Plant Manager
Seven Up Bottling Company Ltd
مجموع سنوات الخبرة :29 years, 11 أشهر
Responsibilities:
Oversee the day to day plant operations which includes Production schedule, Quality Control, Plant Maintenance & Inventory Management for CSD (RGB&PET) & Water lines.
Develop production plans and schedules based on sales forecasts.
Track Overall Equipment Effectiveness (OEE) and productivity Key Performance Indicators (KPIs).
Implement energy-saving and cost-reduction initiatives.
Analyze weekly EPL (Equipment Performance Loss) and OPL (Operation Performance Loss) to enhance productivity.
Overseeing all aspects of factory plant operations, including production and maintenance activities, to ensure smooth and efficient functioning.
Leading a team of production and maintenance personnel, providing guidance, direction, and support to achieve operational objectives.
Developing and implementing strategic plans to optimize production processes, minimize downtime, and maximize output.
Ensuring compliance with safety regulations and standards to maintain a safe working environment for all employees.
Conducting regular inspections and audits of equipment and facilities to identify maintenance needs and address them promptly.
Collaborating with cross-functional teams to address production challenges, resolve issues, and improve overall plant performance.
Monitoring and reviewing key performance indicators (KPIs) related to production efficiency, equipment reliability, and product quality, taking corrective actions on a quarterly basis
Implementing preventive maintenance programs to extend equipment lifespan and minimize unplanned downtime.
Managing budgetary requirements for production and maintenance activities, optimizing resource allocation to meet operational goals.
Driving continuous improvement initiatives to enhance productivity, reduce costs, and streamline processes in the factory plant operations.
Key Achievements:
Initiated a cost reduction project reducing shrink wrap micron size, resulting in an annual saving of $400k million.
Achieved cost savings of $2.5 Million by improving monthly sugar, concentrate, and preform yields.
Successfully completed PI-AIB Audit with a score of 900.
Responsibilities:
Supervised all technical and operational aspects of manufacturing CSD beverages in PET and water lines.
Planned procurement of raw and packaging materials according to monthly sales forecasts.
Tracked OEE and productivity KPIs to optimize manufacturing efficiency.
Led energy-saving and cost-reduction initiatives.
Prepared CAPEX and OPEX budgets, periodically reviewing actual expenses and implementing controls.
Ensured successful implementation and maintenance of the operations ERP module (RAPTEC).
Spearheaded manufacturing operations encompassing both production and maintenance activities within the organization.
Led project management initiatives to drive efficiency, innovation, and sustainability across manufacturing processes.
Managed and optimized production schedules to meet quality standards, delivery deadlines, and cost targets.
Oversaw preventive and predictive maintenance programs to ensure equipment reliability and minimize downtime.
Coordinated with cross-functional teams to execute projects, streamline workflows, and implement best practices.
Identified & implemented process improvements to enhance productivity, reduce waste, and increase operational efficiency.
Key Achievements:
Successfully installed and commissioned a 48, 000 bph KHS CSD line and associated utilities.
Implemented a 1 MW solar PV system at the facility.
Installed and commissioned two 3000 KVA step-down transformers for 11 kV grid power.
Achieved an annual energy saving of $645, 000 through solar utilization.
Attained an annual saving of $300, 000 by replacing plastic layers with carton layers.
Responsibilities:
Managed the end-to-end plant maintenance operations, TPM implementation, process improvement, and project management.
Reviewed and monitored CAPEX and budgeting activities, including value engineering initiatives.
Planned and headed the facility maintenance work and developed streamlined systems to enhance operational effectiveness.
Conducted training sessions on analytical tools and implemented TPM practices in maintenance.
Spearheaded project management initiatives to ensure the successful planning, execution, and delivery of facility management projects.
Oversaw facility management operations and maintenance (O&M) activities to ensure optimal functionality and efficiency of utility systems.
Led cross-functional teams to develop and implement strategies for the effective management of facilities and utilities.
Managed project budgets, timelines, and resources to achieve project objectives and meet organizational goals.
Developed and implemented preventive maintenance programs to enhance the reliability and longevity of facility assets.
Managed maintenance of central A/C, cold stores, and freezers for all Halwani Bros warehouses in the Kingdom.
Key Achievements:
Successfully completed the design, construction, and installation of CSA and MEP projects totaling $30 million for Arabian biscuits (Mamoul), perfume and dry tissues, sugar sachets/sticks, and sugar cube packing facility, covering an area of 13, 000 square meters.
Effectively managed the design, construction, and installation of CSA and MEP projects valued at $150 million for a sesame, tahina, halawa, jam, dairy, and meat facility, spanning across 42, 000 square meters.
Installed and commissioned various manufacturing facilities, including factories for sesame, tahina, meat, jam, dairy, and juice.
Implemented IMS systems (ISO 9001, ISO 14001, OSHAS 18000, FFSC 22000, HACCP) across utilities and facilities.
Job Responsibilities:
• Ensured zero breakdowns, accidents, and quality defects in utilities and production machineries.
• Established and evaluated preventive maintenance programs.
• Implemented TPM and ISO systems in engineering.
• Provided training on Root Cause Analysis (RCA), 5 Why Analysis, and other analytical tools.
• Directed maintenance personnel and coordinated maintenance functions.
• Led project planning, execution, and control activities to ensure the successful delivery of engineering projects.
• Managed project budgets, timelines, and resources to meet quality standards and stakeholder expectations.
• Collaborated with cross-functional teams to develop project scopes, objectives, and schedules.
• Oversaw engineering design, procurement, construction, and commissioning activities to achieve project goals.
• Ensured compliance with safety practices and performed energy management setup changes.
• Led production teams to achieve zero quality complaints and continuous improvement.
Key Achievements:
• Planned and executed projects for Nil Mineral Detergent Bar, surf excel sachets, and auto case packers, among others.
• Achieved a manpower reduction of 54 people through end-of-line automation.
• Added a production capacity of 4000 MT/month for Nil Mineral Bar.
• Constructed a 100 m3/day effluent treatment plant at the Dapada and Daman factories.
Previous Experience
Key Responsibilities:
To lead & enable the Technicians in maintenance department to ensure Optimum availability of equipment for production.
Cost reduction in Maintenance.
Inventory Management for critical & routine spares.
Vendor Development.
Energy Conservation.
Ensure Correct Systems & work practice in plant.
Carried out CBMS & PM Schedule.
Employee Health, safety & Environment.
Developing of subordinates
Key responsibilities:
Oversee the maintenance of Lisec Automatic Glass loading & Cutting Machine, Tam glass tempering machine, Bevilone Beveling machine & polishing machine, Lisec double glazing & Heat mirrors.
Cost reduction in maintenance.
Development of subordinates.
Modern maintenance techniques.
Standardization of equipment’s.
Maintenance of Rotary& Static equipment Like, Pumps, Gear Boxes, Centrifuges, Chiller Compressor, Air Compressor, Boiler, Diesel Generator, Fluid Thermo Heater, Cooling Tower, Fire Hydrant System, Condensers, Over Head Crane, Dryer, Crystallizer etc.
Preventive Maintenance of High Pressure Vessels, Auto claves, Glass Lined Vessels (GLV) Narrators.
Knowledge of Nondestructive testing like Ultrasonic thickness, X-ray, spark Hydraulic etc.
Thermodynamics & Fluid machineries are major subjects
